Boiler Manual - Weil-McLain

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GV90+ gas-fired water boiler — Boiler ManualAnnual start-upAnnual start-up only by qualifiedservice technicianAddress reported problems1. Inspect any problems reported by owner and correct before proceeding.Inspect boiler areaThe boiler should be inspected and started annually,at the beginning of the heating season, onlyby a qualified service technician. In addition, themaintenance and care of the boiler designated inFigure 77, page 67 and explained on the followingpages must be performed to assure maximumboiler efficiency and reliability. Failure to serviceand maintain the boiler and system could resultin equipment failure.Electrical shock hazard — Turn off power tothe boiler before any service operation on theboiler except as noted otherwise in this instructionmanual. Failure to turn off electrical power couldresult in electrical shock, causing severe personalinjury or death.1. Verify that boiler area is free of any combustible materials, gasolineand other flammable vapors and liquids.2. Verify that air intake area is free of any of the contaminants listedin Figure 36, page 30. If any of these are present in the boiler intakeair vicinity, they must be removed. If they cannot be removed,reinstall the air and vent lines per this manual.Inspect boiler interior1. Remove jacket top and front door to inspect interior of boiler.2. Vacuum any sediment and components.Do not use solvents to clean any of the boiler components.The components could be damaged, resulting inunreliable or unsafe operation.Inspect condensate drain system1. Inspect the condensate trap hose for deterioration.2. Check for any obstructions in the trap hose by squeezing thetubing.3. If there is any doubt the condensate drain system is flowing freely,remove the clamp and hose from the bottom of the recuperator.Slide a funnel outlet into the trap hose and pour water through. Itshould exit at the termination of the condensate drain line.Inspect all piping for leaksEliminate all system or boiler leaks. Continualfresh make-up water will reduce boiler life.Minerals can build up in sections, reducingheat transfer, overheating heat exchanger, andcausing heat exchanger failure. Leaking watermay also cause severe property damage.1. Inspect all water and gas piping and verify to be leakfree.2. Look for signs of leaking lines and correct any problemsfound.3. Check gas line using procedure on page 54.Inspect gas piping1. Sniff near floor and around boiler area for any indicationof a gas leak.2. Test gas piping using bubble test, per page 54, ifthere is any indication of a leak.Inspect the water system1. Verify all system components are correctly installed andoperational.2. Check the cold fill pressure for the system. Verify it iscorrect (usually around 12 PSIG).3. Watch the system pressure as the boiler heats up (duringtesting) to ensure pressure doesn’t rise too high.Excessive pressure rise indicates expansion tank sizingor performance problem.4. Inspect automatic air vents and air separators. Removeair vent caps and briefly press push valve to flush vent.Reinstall caps. Make sure vents do not leak. Replace anyleaking vents.Check water system chemistry1. Check system water chemistry (pH and hardness). Seeinstructions beginning on page 59.2. Check glycol and glycol inhibitor levels if using glycol/water mixture. See instructions beginning on page 59.3. Check Sentinel X100 inhibitor level in the water usingthe Sentinel X100 Inhibitor Test Kit. Follow instructionssupplied with the kit. Add X100 inhibitor if needed tobring to the correct level. (See Figure 96, page 89 forpart numbers.)Do not use petroleum-based cleaning orsealing compounds in boiler system. Severedamage to boiler will occur, resulting insubstantial property damage.68Part number 550-142-054/1211
GV90+ gas-fired water boiler — Boiler ManualAnnual start-up (continued)Inspect expansion tank1. Expansion tanks provide space for water to move in and out as theheating system water expands due to temperature increase or contractsas the water cools. Tanks may be open, closed or diaphragm or bladdertype. See page 13 of this manual for suggested location of expansiontanks and air eliminators.• Open-type — located above highest radiator or baseboard unit,usually in the attic or closet. Has a gauge glass and overflow pipeto a drain.• Closed-type — welded gas tight and located above boiler. Tank ispartially filled with water, leaving an air cushion for expansion.• Make sure this type of tank is fitted with a tank fitting, suchas the B & G Tank-Trol or Taco Taco-Trol. This fitting reducesgravity circulation of air-saturated tank water back to the systemand prevents the air from bubbling up through the water as itreturns from the system.• Do not use automatic air vents in systems with closed-typetanks. The air will escape from the system instead of returning tothe tank. Eventually, the tank will waterlog and no longer controlpressurization. The boiler relief valve will weep frequently.• Diaphragm- or bladder-type — welded gas tight with a rubbermembrane to separate the tank pressurizing air and the water. Maybe located at any point in the system, but most often found nearthe boiler.• Systems with this type of expansion tank require at least oneautomatic air vent, preferably located on top of an air eliminator,as shown in examples in this manual.2. If relief valve has tended to weep frequently, the expansion tank maybe waterlogged or undersized.• Closed-type tank — tank is most likely waterlogged. Install atank fitting if not already installed. Then check fill level per fittingmanufacturer’s instructions. If fill level is correct, check tank sizeagainst manufacturer’s instructions. Replace with a larger tank ifnecessary.• Diaphragm- or bladder-type — first, check tank size to be sure itis large enough for the system. If size is too small, add additionaltank (or tanks) as necessary to provide sufficient expansion. If tanksize is large enough, remove tank from system and check chargepressure (usually 12 PSIG for residential applications). If tank won’thold pressure, membrane has been damaged. Replace tank.Inspect air openings1. Verify that combustion and ventilation air openings to the boiler roomand/or building are open and unobstructed. Check operation and wiringof automatic combustion air dampers, if used.2. Verify that boiler vent discharge and air intake are clean and free ofobstructions.Inspect vent system and air piping1. Visually inspect entire flue gas venting system and combustion air pipingfor blockage, deterioration or leakage. Repair any joints that showsigns of leakage in accordance with vent manufacturer’s instructions.When air is ducted to boiler, verify that air inlet hose is connected andproperly sealed.Failure to inspect for the above conditions and have themrepaired can result in severe personal injury or death.Figure 78 Igniter observation port in blowerInspect boiler heating surfacesThe boiler contains ceramic fiber andfiberglass materials. Use care when handlingthese materials per instructionson page 107 of this manual. Failure tocomply could result in severe personalinjury.Electrical shock hazard — Turn offpower to the boiler before any serviceoperation on the boiler except as notedotherwise in this instruction manual.Failure to turn off electrical power couldresult in electrical shock, causing severepersonal injury or death.1. Remove the jacket top panel and jacket front panelafter turning off power to the boiler.2. Remove the two nuts retaining the flueway inspectionport cover (page 3, item g). Remove theflueway inspection port cover.3. Inspect the boiler vent outlet area and heatingsurfaces by looking through the opening.4. If the boiler flueways show accumulation of soot,follow Cleaning boiler heating surfaces onpage 72 to remove the blower housing and cleanthe boiler. If there is evidence of a large accumulationof rusty scale deposits, check the temperaturemixing system.5. Replace the flueway inspection port cover.Inspect igniter1. Verify igniter operation — Look through blowerobservation port (see Figure 78). Access the blowerby removing the boiler jacket front panel if notalready removed.Part number 550-142-054/1211 69
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Boiler Manual - Weil-McLain

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